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Last updated February 17, 2026
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Flat pattern upper assembly: NikeRecent Research Landscape

Traditional footwear assembly relies on labor-intensive stitching of complex 3D components which increases failure points and production time. This approach utilizes flat-pattern geometry and direct-to-substrate printing to eliminate mechanical seams and streamline the manufacturing workflow.

What technical problems is Nike addressing in Flat pattern upper assembly?

Inconsistent textile component alignment

(5)evidences

Manual or static assembly methods lead to misalignment and shifting during the joining of flexible upper materials. Precise stabilization ensures dimensional consistency and reduces manufacturing defects in complex footwear assemblies.

Manual assembly alignment errors

(5)evidences

Inconsistent manual handling and tracking during the final assembly and packing stages. Automating these steps reduces throughput delays and logistical errors in high-volume production.

Inefficient upper assembly waste

(4)evidences

Inconsistent positioning of flat components during stitching or printing leads to structural defects. Precise material gathering and registration prevent geometric distortion in the final footwear shape.